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Cisco AS5300 Series Universal Gateways

Field Notice: FN - 62573 - Routers (AS5350XM, AS5400XM, C180X, C181X, C1841, IAD2400, C2691, C2800NM, C2801, C3725, C3745, C3800, VG224) Unable to Read Compact Flash - ROMMON Upgrade Available


Revised March 12, 2008

April 26, 2007

NOTICE:

THIS FIELD NOTICE IS PROVIDED ON AN "AS IS" BASIS AND DOES NOT IMPLY ANY KIND OF GUARANTEE OR WARRANTY, INCLUDING THE WARRANTY OF MERCHANTABILITY. YOUR USE OF THE INFORMATION ON THE FIELD NOTICE OR MATERIALS LINKED FROM THE FIELD NOTICE IS AT YOUR OWN RISK. CISCO RESERVES THE RIGHT TO CHANGE OR UPDATE THIS FIELD NOTICE AT ANY TIME.


Products Affected

Product

CISCO1801

CISCO1802/K9

CISCO1802W-AG-E/K9

CISCO1803/K9

CISCO1803W-AG-A/K9

CISCO1803W-AG-E/K9

CISCO1811/K9

CISCO1812/K9

CISCO1841

CISCO2691

CISCO2801-ADSL/K9

CISCO2801-SEC/K9

CISCO2811

CISCO2821

CISCO2851

CISCO3725

CISCO3745

CISCO3825

CISCO3845

AS5350XM

AS5400XM

IAD2430-24FXS

IAD2431-16FXS

IAD2431-1T1E1

IAD2431-8FXS

IAD2432-24FXS

SPIAD2430-24FXS

SPIAD2431-16FXS

SPIAD2431-1T1E1

SPIAD2431-8FXS

SPIAD2432-24FXS

VG224

Problem Description

The compact flash (CF) contained in specific Cisco routers may contain a defect preventing access to the Compact Flash and could cause a boot failure following a power cycle or reload. During a failed state the router will be unable to pass traffic. Cisco is providing a ROM Monitor (ROMmon) update that resolves this scenario.

Background

The Compact Flash modules were installed in specific Cisco routers that were manufactured between May 2005 and October 2006. In addition, spare Compact Flash Modules shipped individually between May 2005 and October 2006 may exhibit this problem.

This issue has been linked to a Compact Flash vendor manufacturing problem. The root cause was identified and appropriate steps have been taken to resolve the problem. An upgrade to the router ROM Monitor (ROMmon) is available as a solution.

Flash cards that were upgraded in the field or moved to a different chassis should be checked with the validation steps below.

Problem Symptoms

The problem symptom is typically seen during a system reload or cold start. Under normal circumstances a router's Compact Flash could contain Cisco IOS software, configurations or other files necessary for system boot or operation. These files are accessed by the router during the boot sequence to reach an operating state.

In the problem state, the router is unable to access the contents of the Compact Flash. When the problem occurs, the system is prevented from accessing information stored on the Compact Flash. This type of error occurs in the controller of the Compact Flash. Data stored on the Compact Flash should be intact but may not be accessible. The router may indicate the state with a message log below. The router will be unable to read the contents of the Compact Flash that was previously operational.

The output below shows the system log or terminal monitor message when the router is unable to read the Compact Flash contents.

%Error opening slot0:/ (No device available)

Note: The Router will be unaffected and continue to run with a failed flash disk showing %Error opening slot0:/... . Only read/write access such as a logfile write to the flash disk or a router reboot will cause the following problem symptom to become evident.

The router may stop the boot sequence and remain at a ROM Monitor (ROMmon) prompt as seen below.

Readonly ROMMON initialized  
boot: cannot open "flash:"  
boot: cannot determine first executable file name on device "flash:"  
cxxxx processor with 524288 Kbytes of main memory Main memory is configured to 64 bit mode with ECC enabled   
Readonly ROMMON initialized  
rommon 1 >

Workaround/Solution

Cisco has made an update to the router ROM Monitor (ROMmon) software that resolves the scenario described in the Problem Symptoms section of this field notice. This fix allows the contents of the Compact Flash to be read by the router during the boot sequence.

AS5400XM/AS5350XM ROMMON Upgrade: AS5400XM_RM2.srec.123-12r.T2 (registered customers only)

C1800/C1810 Series ROMMON Upgrade: C1800_RM2.srec.123-8r.YH12 (registered customers only)

C1841 ROMMON Upgrade: C1841_RM2.srec.124-13r.T5 (registered customers only)

C2400 ROMMON Upgrade: C2400_RM2.srec.124-13r.T5 (registered customers only)

C2691 ROMMON Upgrade: C2691_RM2.srec.124-13r.T5 (registered customers only)

C2800NM ROMMON Upgrade (2811, 2821, 2851): C2800NM_RM2.srec.124-13r.T5 (registered customers only)

C2801 ROMMON Upgrade: C2801_RM2.srec.124-13r.T5 (registered customers only)

C3725 ROMMON Upgrade: C3725_RM2.srec.124-13r.T5 (registered customers only)

C3745 ROMMON Upgrade: C3745_RM2.srec.124-13r.T5 (registered customers only)

C3800 ROMMON Upgrade: C3800_RM2.srec.124-13r.T5 (registered customers only)

VG224 ROMMON Upgrade: VG224_RM2.srec.124-13r.T5 (registered customers only)

DDTS

To follow the bug ID link below and see detailed bug information, you must be a registered user and you must be logged in.

DDTS

Description

CSCek51210 (registered customers only)

Compact Flash failure observed after power outage

How To Identify Hardware Levels

Overview of Steps to Validate Product

fn62573_jceniq.jpg

Follow the steps below to validate if your product is affected by this field notice. There are two methods, chassis serial number and inspection of compact flash, to validate if the Compact Flash is affected:

  1. Confirm Product ID and serial number range in the table below.

  2. Visual inspection of compact flash is recommended if the flash is not currently installed in a router or the router is powered off. Note that powering down an affected router could trigger the symptom causing the router to remain at a ROM Monitor (ROMmon) prompt. If the visual inspection of the Compact Flash does not fit the description below and the problem is still happening then this is the result of some other issue.

  3. IOS inspection of compact flash is recommended if the router is currently running. If the inspection of IOS does not fit the description below and the problem is still happening then this is the result of some other issue.

    Note: If geometry and format information is not displayed, the card is formatted with a Class B Flash file system (LEFS) and steps to interrogate CF via IOS in this field notice do not apply.

    Note: If the result of IOS command cylinder check is showing a completely different cylinder count than the numbers in the chart, like 65553, this could indicate a problem with the compact flash. In these cases, Visual Inspection (Step 1.a) of the suspect compact flash can be performed to validate if a ROMmon upgrade should be performed.

    An Example of IOS Inspection:

    9-4-2800-1#sh flash: filesys
    ******** ATA Flash Card Geometry/Format Info ********
    
    ATA CARD GEOMETRY
    Number of Heads: 8
    Number of Cylinders 490
    Sectors per Cylinder 32
    Sector Size 512
    Total Sectors 125440
    

    Note: If during IOS inspection an %Error show flash: message is seen after performing a show flash:filesys , the CF symptom may have occurred or the CF may have failed due to physical damage unrelated to this notice. In this case a ROMmon upgrade is required to avoid a failure during the next system reboot. If the new ROMMON upgrade fails, then the CF may need to be replaced.

Visual Inspection - Locate the Manufacturing Part Number Prefix and the Manufacturing Production Code on the Compact Flash. The image below shows the code locations on the Compact Flash.

Note: If Compact Flash is no longer paired with its original router (due to upgrade or other reasons) proceed with "Step 1" below.

Manufacturing Code Locations

Location A - Manufacturing Part Number Prefix

Location B - Manufacturing Production Code (format Year - Month - Day)

fn62573_j9hd1b.jpg

fn62573_jhqoi9.jpg

How To Upgrade Software

Special instructions for downloading ROMmon image:

  1. If the compact flash is good, download the ROMmon file to compact flash on the router and then issue the upgrade rom-monitor file command to download the file from compact flash.

  2. If the compact flash is bad, increase the exec and session timeout for TTY/VTY lines in the running configuration by issuing the following configuration commands:

    exec-timeout 60

    session-timeout 60

ROM Monitor download procedures:

Cisco AS5350XM and Cisco AS5400XM Universal Gateways Software Configuration Guide

ROM Monitor Download Procedures for Cisco 2691, Cisco, 3631, Cisco 3725, and Cisco 3745 Routers

Cisco 1800, 2800 and 3800 Series Integrated Services: Use same procedure as 2691, 3631, 3725 and 3745

ROM Monitor Download Procedures for Cisco IAD2430 Series Integrated Access Devices IADs

ROM Monitor Download Procedures for Cisco VG224 Voice Gateways

Frequently Asked Questions

Q1 - Will formatting the Compact Flash resolve this issue?

A1 - No, attempts to format the Compact Flash will not resolve the problem. When the problem occurs data should be intact and re-formatting after applying the solution should not be necessary.

Q2 - I've applied the solution, but my router does not boot. What do I do?

A2 - There may be a separate issue preventing the router from booting. Further troubleshooting may be necessary.

Q3 - If I swap a suspect bad CF into a different router will it work?

A3 - A router that does not contain the ROMMON update may not boot with a compact flash that is affected by the problem.

Q4 - What do I do if my router is currently in ROMMON mode?

A4 - Reference the Cisco Tech Tip for instructions on booting the router using TFTP or use another compact flash.

Q5 - During Visual inspection if I see one of the three criteria does not apply is my part still potentially bad?

A5 - No, all three criteria must match the Field Notice. If any of them do not match the criteria then product is not subject to the notice.

For More Information

If you require further assistance, or if you have any further questions regarding this field notice, please send an e-mail to fn62573-support@cisco.com.

Revision History

Revision

Date

Comment

1.9 12-MAR-2008 Updated C1801 to CISCO1801 in the Products Affected section.

1.8

17-OCT-2007

Updated link for Cisco AS5350XM and Cisco AS5400XM Universal Gateways Software Configuration Guide.

1.7

09-JUL-2007

Added CISCO1803W-AG-E/K9 to the Products Affected section.

1.6

02-JUL-2007

Added the following to Products Affected section: CISCO1802W-AG-E/K9, CISCO1803W-AG-A/K9, CISCO2801-ADSL/K9, and CISCO2801-SEC/K9.

1.5

25-MAY-2007

Added Special instructions for downloading ROMmon image to the How to Upgrade Software section.

1.4

14-MAY-2007

Added note to step 3 and added format example "(format Year - Month - Day)" in last section on manufacturing code in How to Identify Hardware Levels section. Added question 5 to Q & A section.

1.3

08-MAY-2007

Updated chart in How to Identify Hardware Levels section to include 512MB CF information.

1.2

02-MAY-2007

Updated link for Cisco 1800, 2800 and 3800 Series Integrated Services in How to Upgrade Software section.

1.1

27-APR-2007

Changes made to Problem Symptom, How to Identlfy HW Level, Workaround/Solution and How to Upgrade Software sections.

1.0

26-APR-2007

Initial Public Release

For More Information

If you require further assistance, or if you have any further questions regarding this field notice, please contact the Cisco Systems Technical Assistance Center (TAC) by one of the following methods:

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